Pile fabric



May 6, 1969 s. PLOCH ET AL 3,442,101

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May 6, 1969 s, p og ET AL 3,442,101

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FILE FABRIC Filed April 1, 1965 Sheet INVENTO RS IflFQ'FP/[D 200/ UnitedStates Patent 3,442,101 PlLE FABRIC Siegfried Ploch, Waiter Scholtis,and Heinz Zschunke,

Karl-Marx-Stadt, Germany, assignors to Forschungsinstitut fiirTextiltechnologie, Karl-Marx-Stadt, Germany Filed Apr. 1, 1965, Ser. No.444,640 lint. Cl. D041) 7/12, 9/12, 11/08 US. Cl. 66-194 4 Claims Thepresent invention relates to textile webs which have a fiber layerarranged on a base or foundation, as well as to a device and process forjoining the base with the fiber layer by means of parallel seams offiber loops extending in the direction of movement of the Web throughthe device.

It is known to sew fleeces to a base web with the aid of sewing threads.This results in insufiicient properties for use as the fibers are notanchored firmly enough in the fabric bond. Moreover, because of thesewing threads, an additional thread system is required.

Another known process envisages the needling up of fleeces on a basewith the aid of multi-needle machines having needles with small barbs.These needles penetrate from the side of the fleece through the twomaterials to be joined and on their return take along a number of fibersas, for example, in the form of fiber loops. These loops are put down onthe top side of the fleece in a quilting stitch manner and compress thefleece in an unwanted manner. The fleece is connected with the base onlyby those fibers which have been pulled through to the side opposite thefleece and which form little knots thereat. The connection between thefleece and the base is not very strong.

In another known process, fiber tufts are bound into knit fabrics,simultaneously with the production thereof, by means of circularknitting machines. For this purpose the machine has on its circumferencebetween four and eight miniature cards to which a fiber band issupplied, and which deliver the fibers coming from the band into theneedles of the knitting machine. The output of this type of machine isrelatively low, and the resulting product has at first the property of amesh fabric which must subsequently be stabilized by subsequentfinishing. Moreover, with such machines only the connection betweenfiber tufts and a knit fabric is possible, while the sewing in of thefiber tufts, for example, in foam material or fleece fabric webs cannotbe accomplished by this method.

Methods are also known for gluing pleated fleeces on a base or betweentwo base webs. The disadvantages of this method are that an adhesive isneeded, that the product becomes rather stiff, and that the airpermeability and hence the respiratory activity of the product areimpaired by the gluing.

Finally, it is known to sew fleeces in the form of longitudinal ribs ona base web by means of nap-forming elements. Sewing threads are againneeded, and the fibers are held only by the pressure between sewingthreads and base web so that they are not firmly anchored in the baseitself.

It is the object of this invention to provide a textile web in which afiber layer is connected with a base or foundation without sewingthreads, providing high strength, without constricting the fiber layerin the manner of a quilting stitch seam; as well as a device and aprocess for making this novel web.

According to an important feature of the invention, the base and thefiber layer are connected by means of fiber loops which are pulled outof the fiber layer and formed into wales or chain-stitch seams andarranged on the back of the base or foundation. The fibers are iceoriented in the fiber layer, preferably lengthwise or transverse to thedirection of movement of the web.

The base is a woven, knitted, fleece, foam material or similar web.Alternatively, it may be formed of a loose layer of longitudinal and/ ortransverse threads. The transverse and longitudinal threads are arrangedin crossed superposition and are mutually interconnected by means of thefiber loops pulled out of the fiber layer, and finally connected withthe fiber layer itself.

In the process for the production of the textile web, according to theinvention, the fiber loops are pulled out of the fiber layer by means ofslide, latch, or other suitable reciprocating needles of multi-needlemachines.

In the inventive device, the fiber layer is pushed into the hooks of theneedles by suitable means, e.g. by way of a roller fitted completely orpartly with brushes. The roller rotates continuously or synchronouslywith the needles, by means of a rod or rail executing a swingingmovement synchronously with the needle cycle. The roller may be fittedwith brushes, or by a similarly functioning pressure rod which may alsobe designed in the form of a pressure comb.

The tips of the needles enter into the fiber layer from the side of thebase, pull the seized fibers through the base on their return, and formfrom these fibers, a fiber loop held by the needle hooks. As has beenmentioned, the base may consist of a woven, knitted, fleece, or foammaterial, or of a layer of longitudinal or transverse threads or fibers,or of loosely superimposed longitudinal and transverse threads.

When the needles occupy their rearmost position and their hooks areclosed, the previously formed fiber loops still present on the needleshanks are cast off over the previously mentioned new fiber loops. Inthis way a portion of the fiber material is present as wales or chainstitch seams on the side of the base away from the fiber layer, and thusestablishes a firm connection between the fiber layer and the base. Thisconnection is much more intimate due to its mesh-like, non-ravelingarrangment than can be achieved with the known needling.

The fibers may also be pulled out of the fiber layer in such manner sothat separate fiber tufts are formed which are tied into the base-likeknitting stitches. The fiber tufts result in a plushor fur-like surface.By increasing the rate of supply of the fiber layer in relation to thatof the base web about four to tenfold, the fiber layer can be compressedin transverse direction or even pleated in rib form.

By the use of nap-forming means, e.g. nap sinkers, between the needlesof the novel device, an arrangement in the form of longitudinal ribs canbe obtained.

The fiber layer of the textile web according to the invention may alsoconsist of two or more fiber layers, the fibers in the layer toward theneedles'being, for example, substantially longitudinally oriented, whilethe fibers in the outer layer are oriented substantially slantwise tothe direction of movement of the web. Then substantially only thetransversally oriented fibers are seized by the needle hooks and bindthe longitudinally oriented fibers in, together with the above-mentionedloose fiber layers.

The textile web according to the invention can be finished in variousways, for example, it is possible to roughen it, shear it, or full it.The base and/or the fiber layer may consist wholly or partly ofshrinkable fiber materials, known per se. The textile web thus producedcan then be subjected to a shrinkage treatment resulting in a thickeningof the fiber layer.

The advantages of the textile web, process and device according to thepresent invention are the following: The connection of the fiber layerwith the base is achieved without sewing thread but with substantialpreservation 3 of the voluminosity of the fiber layer, from which arough, high pile, or similar surfaces can be achieved in a particularlyfavorable manner. There are no quilting-seam type constrictions. Also,the nap formation itself occurs without the use of spun products orthreads, using only the fibers of the fiber layer, so that for this partof the textile web the spinning process and the preparatory operations,

' such as reeling and warping, are also eliminated.

No special machines are necessary, as the device required for carryingout the process, for feeding the fiber layer and for introducing thefibers into needle hooks, is relatively simple and can easily beattached to known multi-needle machines. For the production of thetextile Web according to the invention there is used a multineedlemachine which in its output is superior to the known looms and knittingmachines.

The invention permits the manufacture of a plurality of products, suchas velours, padded overcoat materials, blankets, fur imitations,plushes, and carpets.

The products according to the invention have a high voluminosity as thefiber material is not pressed into a spun system. Thereby major airinclusions are obtained, which result in a higher heat holding capacitythan with the use of yarns or compressed fleeces. Due to the fact thatthe proportion of fibers taken along on the side of the base away fromthe fiber layer can be controlled, a bilateral arrangement of a fiberlayer on the base is obtained, the fibers being present on one side infleece, nap, or tuft form and on the other side in the form of knittedstitches. Depending on the quantity of fibers participating in thestitch formation, the stitch side, too, can be given a plushorblanket-like finish.

The control of the proportion of fibers of the fiber layer formed intostitches can be effected in the inventive process and device, amongother things, by the size of the needle hooks, by the timing of thecovering of the needle hooks inside or outside the fiber layer, by theregulation of the speed and amount of movement of the means for pressingthe fiber layer into the needle hooks, by the height of the nap or plushsinkers, by the mass of the fiber layer, and by the rate of their feed.

Other objects and advantages of the invention will be appreciated andmore fully understood with reference to the following detaileddescription, when considered with the accompanying drawings, wherein:

FIG. 1 is a somewhat schematic, cross-sectional view of a work positionof the device according to the invention, forming part of a multi-needlesewing-knitting machine, with slide needle, brush roller and fabricfeed;

FIGS. 2a and 2b illustrate a tubular and latch needle, respectively,which can also be used in the inventive device;

FIG. 3 is a view similar to that of FIG. 1 of an alternative deviceaccording to the invention, having a brushfitted rod or rail therein;

FIG. 3a is a fragmentary cross-sectional view along line III-III of thesinkers 14 of FIG. 3;

FIGS. 4a and 4b show a pressure rod and a pressure comb, to be used inthe inventive device in lieu of brushes as shown in FIG. 3;

FIG. 5 is a plan view of the drive for the needles, the closing wiresand also for the brush-fitted rail of FIG. 3;

FIG. 6 is a partial sectional view of the drive shown in FIG. 5, takenalong line 66;

FIGS. 7a-7d shows, in longitudinal sectional views, various forms oftextile webs made according to the invention, with the devices of FIGS.1 and 3, and having a woven fabric as a base;

FIG. 7e is a plan view of the textile web according to FIG. 7d;

FIG. 8 is a view similar to that of FIGS. 1 and 3 of another alternativedevice using an array or layer of longitudinal and transverse threads asa base; and

FIG. 9 is a longitudinal sectional view, similar to those 4 of FIGS.7a-7d, of a textile web produced with the device of FIG. 8.

FIG. 1 of the drawings shows a first embodiment of the work position ofthe device according to the invention, forming part of a multi-needleknitting machine also capable of sewing stitches. As shown in thesomewhat schematic view, the device comprises a plurality of slideneedles 11 arranged on a common bar 21, the needles having hooks (seethe enlarged views of FIGS. 2a and 2b). For closing the hooks, wires 12are provided on a bar 22. The conventional means serving to reciprocatethe needles 11 and the closing wires 12 have not been illustrated;reference to an appropriate drive mechanism will be made when describingFIGS. 5 and 6.

This type of device uses a woven fabric as a base, shown at 60, to whichis applied a fiber layer 70, as will be explained in more detail. Thislayer preferably consists of fibers oriented substantiallylongitudinally or transversally to the direction of advance. The exit ofthe slide needles 11 from the base 60 is ensured by cast-off sinkers 13,secured to a bar 23. The fiber layer 70 is laid over nap or plushsinkers 14 supported by a bar 24.

The fabric 60, serving as a base, is fed continuously to the device, asis the fiber layer 70. The latter is continuously delivered by means ofrotating feed rollers 18, one of them entraining an endless conveyorcloth 28 which also passes over a roller 19 in the region of the workstation. The fiber layer 70 may, however, also be fed directly to thesewing-knitting station by a card (not illustrated) workingsynchronously with the machine.

The slide needles 11 pass through the base 60 and seize with their hooks11a fiber tufts from the fiber layer 70, when they have reached theirforemost position (as illustrated). The fiber layer 70 is brought intothe form of nap-like longitudinal ribs by the cooperation of the sinkers14. The fibers are pushed into the hooks 11a of the needles 11 by arotating brush roller 20 so that the needles, on their return, takealong the fiber tufts from the fiber layer 70, pulling them through thebase 60.

In the hooks 11a of the slide needles 11 these fiber tufts forrn fiberloops 75 over which the previously formed fiber loops are cast off inthe rearmost position of the needles when their hooks 11a are closed bythe wires 12. There are thus formed closed wales or chain-stitchedseams, and the reverse side of the textile web according to theinvention has the appearance of a mesh fabric, as will be explainedfurther as the description proceeds.

FIG. 3a is a fragmentary cross-sectional view along IIIIII of thesinkers 14 of FIG. 3 looking into the direction of arrows. It is seenthat loops 75 are formed around the respective sinkers 14, 14 and 14"with legs passing over the base fabric 60.

Instead of the previously made woven or other type of base fabric asshown at 60, a knit, a fleece, or a foamed web may be used with thedevice illustrated in FIG. 1.

It should be noted that instead of the slide needles 11 shown in FIGS.1, 3 and 8, tubular needles 11' or latch needles 11" may be used (seerespective FIGS. 2a and 2b). In the former, a closing member 11b mayslide back and forth for opening the hook 11a. In the latter, a latch11c is provided in a known manner for the same purpose. It is understoodthat the afore-mentioned closing wires 12 are adapted to co-operate withthe alternative types of needles as well.

FIG. 3 shows an alternative or second embodiment of the device accordingto the invention, wherein most elements are identical with those alreadydescribed for FIG. 1, and have, accordingly, been given identicalreference numerals. Instead of the previous rotating brush roller 20,however, this device has a rod or rail 50 which carries a plurality ofsmall brushes 40. The rail 50 is made to carry out an up-and-downswinging movement in unison with the longitudinal reciprocation of theneedles 11, as indicated by the appropriate arrows.

Instead of brushes, rail 50 may carry a pressure rod 40' as shown inFIG. 4a or a pressure comb 40", as illustrated in FIG. 4b. The rod 40 ispreferably equipped with a foam or rubber covering (not shown). Itshould be noted that both the rail 50 and the needle bar 21 may beprovided with appropriate, conventional holders for releasableattachment of the respective brushes and needles, as has beenschematically shown in FIG. 5.

FIGS. 5 and 6 illustrate an exemplar embodiment of the drive mechanismfor the needles 11, the wires 12 and particularly for the brush rail 50of the device of FIG. 3. It should be noted that this drive mechanismhas been shown in FIGURES 4 and 5 of US. Patent 3,030,786 to H.Mauersberger, with a reissue Patent Re. 25,749 dated Mar. 23, 1965,entitled Textile Material and Manufacture, and co-assigned with thepresent application. In the present FIGS. 5 and 6, correlated referencenumerals have been used (e.g. 111 instead of 11, or 150 instead of 50 asused in the earlier patent).

The drive mechanism employs, for purposes of rapid machine operation,circular eccentric cams for actuating the needles 11, the closing wires12 and the brushes 40. As shown in FIG. 5, the needle bar 21 carryingthe needles 11 is actuated by a connecting rod 113 extending from aneccentric rod 112 linked to a strap 112a of an eccentric cam 111 whichis rotated by a motor-driven shaft 110 supported by a housing 150.

Similarly, the reciprocating movement of the closing wires 12 isobtained by means of an eccentric cam 115 cooperating with a strap 142aactuating, through an eccentric rod 142, a connecting rod 143 thatactuates the bar 22 which carries wires 12. The connection between rod143 and bar 22 has been broken away for the sake of clarity.

The rail 50, carrying brushes 40, is fixedly mounted on a shaft 120 bymeans of suitably attached lever arms 117. Shaft 120, being rotatablymounted within bearings 119, is adapted to slide longitudinally back andforth, within certain limits, and carries a short lever 121. The latteris connected with a coupling rod 122 linked to an eccentric rod 124.This rod, with its strap 124a, encloses an eccentric cam 125 which, bymeans of an intermediate connecting rod 123, moves the brushes 40 up anddown.

Aside from this reciprocating movement, the brushes must preferablyundergo an axially transverse back and forth movement. The brushes 40and the shaft 120 carrying the rail 50 therefore are preferably operatedto perform one complete back and forth movement while the needles 11 aremoved twice back and forth. To accomplish this, a pinion 126 keyed tothe shaft 110 engages a spur wheel 127 of twice its size. Consequently,the spur wheel rotates at one half of the speed of the shaft.

The spur wheel 127 is fixedly connected with an eccentric cam 128 whosestrap member 129a is lined by an eccentric rod 129 to a connecting rod131, axially slidable in bearing 130. When in operation, the rod 131 andits linkage 131a impart axial reciprocation to the shaft 120 byactuating an angle lever 133 rotatably mounted on a pivot 132. A tensionspring 134 positioned around the shaft 120 between one of the bearings119 and the adjacent lever arm 117 of the rail 50 aids the axiallyoscillating movement by forcing the shaft against an adjusting screw 135connecting the free end of angle lever 133 to that of shaft 120.

In carrying out the new textile-web making process according to thepresent invention, the fibers of layer 70 may be given a much greaterlength than that consumed in each working cycle, so that they are seizedseveral times in succession by the needles, namely successively byseveral needles standing side by side, owing to the lateral movement ofrail 50, as has been described before. This results in lockedchain-stitch seams which solidly connect the fiber layer 70 with thebase 60, and which do not unravel.

FIGS. 7a through 7d show various longitudinal sections of textile websmade according to the invention, with FIG. 7e representing a plan viewof the web according to FIG. 7d. These variants can be produced with thedevices according to FIGS. 1 and 3. In the alternative of FIG. 7a, thebase 60 is connected with a closed fiber layer 70a by means of the fiberloops 75. As shown in FIG. 7a the fiber loops 75 are substantiallyU-shaped in form, and adjacent loops are interconnected together at theside of base 60 disposed away from fiber layer 70a. In this manner fiberlayer 70a is firmly secured to base 60.

In the second alternative according to FIG. 7b, separate twistless fiberbundles are pulled out of the plush fiber layer 7011, fed to the workingstation in closed form. These bundles are anchored in the base 60 bymeans of the substantially U-shaped fiber loops 75. The leg portions ofthe loops 75 are passed through a single opening in base 60. Adjacentloops 75 are interconnected to one another to thereby secure the fiberlayer 70b to the base 60. The fiber bundles or tufts 90, extendinguniformly throughout fiber layer 70b, form a plushor fur-like websurf-ace.

In the form of web shown in FIG. 7c, a crosswise pleated fiber layer 7%is utilized, that is the twistless fibers of layer 70c are folded overone another to achieve a greater thickness of fiber as shown in FIG. 70,the pleating being crosswise to the direction of movement of the web.The layer is connected with the base 60 by means of the loops 75. Thepleating has been obtained in that the fiber layer 70 has been fed tothe device at a speed increased by about four to tenfold as compared tothe fabric base 60.

In the fourth alternative appearing in FIGS 7d and- 72, the fiber layerconnected with the base 60 by means of loops 75 consists of two layers,namely 70d and 70d. The fibers in layer 70d are oriented substantiallyin the direction of movement of the web, while the fibers in layer 70dare oriented substantially perpendicularly thereto. In the plan view ofFIG. 7e the stitch lines in course 70d are indicated by broken lines 75'.

A modified or third embodiment of the inventive device is illustrated inFIG. 8 wherein, again, identical elements have been designated with thesame numerals as in FIGS. 1 and 3. This device permits the use of looselongitudinal and transverse threads or fibers in crossed superposition,instead of woven or knitted fabrics or the like, as a base fabric 60 forthe novel textile web. Such a base 60 is illustrated as consisting ofcross threads 61, supplied continuously to the device by means ofendless needle chains 62. Longitudinal threads 63 are continuously fed,in the manner of a warp-thread group, in a manner to be describedsomewhat later.

Closing wires 12' have been alternatively illustrated, secured to bar22, which are somewhat different from the wires 12 of the previousembodiments. Cast-off sinkers 13' are provided on bar 23, somewhatlonger than sinkers 13 illustrated and described before. Additionally,the device of FIG. 8 is fitted with counter-holders 15 held by a commonbar 25, and a counter-holder rod 16. As clearly shown in the drawing,the fiber layer 70 is guided between these last-named elements. Forintroducing the warp-wise threads 63, eye needles 65 are providedbetween the counter-holders 15 and the path of the layer 70; theseneedles are also held by bar 25.

The device operates as those described before. By means of the feedrollers 18 and the conveyor cloth 28, driven by one of the feed rollersand guided around roller 19, the fiber layer 70 is supplied continuouslyto the work position of the machine. The feed of the fiber layer may,however, also be effected directly by a card. (not illustrated) workingsynchronously with the sewing-knitting machine.

When the needles 11 have reached their foremost position, asillustrated, the fibers of layer 70 are pushed, by the rotating brushroller 20, into the hooks 11a of the needles. On their return, theneedles take along these fiber tufts.

In the hooks 110, the fiber tufts form fiber loops 75 over which thepreviously formed fiber loops are cast off by means of sinkers 13 in therearmost position of the needles 11, in which the hooks are closed bythe wires 12'. The cast-off sinkers 13' ensure, moreover, the exit ofthe needles 11 in their rearmost position from the layer 70 and the baselayer 60 (including threads 61 and 63). The counter-holder 15 and thecounter-holding rod 16 facilitate the passage of the needles 11 duringtheir forward movement through the threads 61, 63 and fiber layer '70.

It will be understood, of course, that needles 11' and 11" might as wellbe used in this embodiment of the inventive device, too. Also,alternately, individual brushes 40 on a bar could be incorporatedinstead of the rotating brush roller 20.

FIG. 9 shows a textile web made with the use of the device of FIG. 8,utilizing threads as a base or foundation. The transverse threads orfibers 61 and the longitudinal threads 63 constitute the base they areconnected with the fiber layer by way of fiber loops 75. It should benoted, however, that the connection of the layers can also be effectedin the manner shown in FIGS. 717 through 7d.

The foregoing disclosure relates only to preferred, exemplaryembodiments of the invention, which are intended to include all changesand modifications of the examples described within the scope of theinvention.

We claim:

1. A textile fabric comprising:

(a) a base; and

(b) a pile layer comprising a plurality of rows of fiber bundlesextending along one side of said base in at least one direction, each ofsaid rows comprising a plurality of substantially twistless fiberbundles secured to said base by extending portions of said bundlesthrough said base to the other side thereof to form, with portions ofadjacent bundles, at least two interconnected rows of knitted loopsextending in the same direction as the rows of fiber bundles of whichthey are a part, each of said bundles comprising fibers of a lengthsufficient to extend into at least two adjacent rows of said knittedloops.

2. A textile fabric as defined in claim 1, wherein said rows of fiberbundles constitute a pleated layer, the pleats in said pleated layerbeing at least partly transversal to the longitudinal run of the textilefabric, said portions extending through said base forming chain stitcheson said other side of said base.

3. A textile fabric as defined in claim 1, wherein said base consists ofa knitted fabric.

4. A textile fabric as defined in claim 1, wherein at least a portion ofsaid base is constituted of a shrinkable material.

References Cited UNITED STATES PATENTS 271,539 1/1883 Straw. 1,314,5659/1919 Billington 2827.2 1,334,744 3/1920 Farr 16180 2,672,673 3/1954Shaw 2872.2 X 2,881,505 4/1959 Hofiman 287-2.2 2,978,786 4/1961 Turner28--72.2 3,174,308 3/1965 Mauersberger 66-192 3,260,640 7/1966 Owen28--72.2 X 3,274,806 9/1966 Duhl 66192 3,168,883 2/1965 Ploch et a1.112-411 3,309,901 3/1967 Danhel et al.

FOREIGN PATENTS 236,272 7/ 1925 Great Britain.

853,867 12/1939 France.

900,056 12/1953 Germany.

ROBERT R. MACKEY, Primary Examiner.

US. Cl. X.R.

1. A TEXTILE FABRIC COMPRISING: (A) A BASE; AND (B) A PILE LAYERCOMPRISING A PLURALITY OF ROWS OF FIBER BUNDLES EXTENDING ALONG ONE SIDEOF SAID BASE IN AT LEAST ONE DIRECTION, EACH OF SAID ROWS COMPRISING APLURALITY OF SUBSTANTIALLY TWISTLESS FIBER BUNDLES SECURED TO SAID BASEBY EXTENDING PORTIONS OF SAID BUNDLES THROUGH SAID BASE TO THE OTHERSIDE THEREOF TO FORM, WITH PORTIONS OF ADJACENT BUNDLES, AT LEAST TWOINTERCONNECTED ROWS OF KNITTED LOOPS EXTENDING IN THE SAME DIRECTION ASTHE ROWS OF FIBER BUNDLES OF WHICH THEY ARE A PART, EACH OF SAID BUNDLESCOMPRISING FIBERS OF A LENGTH SUFFICIENT TO EXTEND INTO AT LEAST TWOADJACENT ROWS OF SAID KNITTED LOOPS.